Fayat Group BOMAG BP 12/40 User manual

Operating instructions
Maintenance instructions
Catalogue number
008 059 01 06/2008
BP 12/40 / BP 20/50 / BP 25/50
S/N 101 230 01 .... >S/N 101 230 03 .... > S/N 101 230 05 .... >
Vibratory plate
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Foreword
BOMAG 3BP 12/40, BP 20/50, BP 25/50
F oreword
BOMAG machines are products from the wide
range of BOMAG compaction equipment.
BOMAG’s vast experience in connection with
state-of-the-art production and testing meth-
ods, such as lifetime tests of all important
components and highest quality demands
guarantees maximum reliability of your ma-
chine.
Using these instructions will
lhelp you to become familiar with the machine.
lavoid malfunctions caused by unprofessional
operation.
Compliance with the maintenance instructions will
lenhance the reliability of the machine on con-
struction sites,
lprolong the lifetime of the machine,
lreduce repair costs and downtimes.
BOMAG will not assume liability for the function of
the machine
lif it is handled in a way not complying with the
usual modes of use,
lif it is used for purposes other than those men-
tioned in these instructions.
No warranty claims can be lodged in case of dam-
age resulting from
loperating errors,
linsufficient maintenance and
lwrong fuels and lubricants.
Please note!
This manual was written for operators and mainte-
nance personnel on construction sites.
You should only operate the machine if you are ful-
ly acquainted with the contents of these instruc-
tions.
Strictly observe the safety regulations.
Please observe also the guidelines of the Civil En-
gineering Liability Association ”Safety Rules for
the Operation of Road Rollers and Soil Compac-
tors” and all relevant accident prevention regula-
tions.
For your own personal safety you should only
use original spare parts from BOMAG.
In the course of technical development we re-
serve the right for technical modifications
without prior notification.
These operating, maintenance and repair instruc-
tions are also available in other languages.
Apart from that, the spare parts catalogue is avail-
able from your BOMAG dealer against the serial
number of your machine.
Your BOMAG dealer will also supply you with in-
formation about the correct use of our machines in
soil and asphalt construction.
The above notes do not constitute an extension of
the warranty and liability conditions specified in the
general terms of business of BOMAG.
We wish you successful work with your BOMAG
machine.
BOMAG GmbH
PrintedinGermany
Copyright by BOMAG
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Foreword
BOMAG4BP 12/40, BP 20/50, BP 25/50
Please fill in
............................
Machinetype(Fig.1)
............................
Serial No. (Fig. 1 and 2)
............................
Engine type (Fig. 3)
............................
Engine No. (Fig. 3)
i
Note
Fill in the above listed data when receiving the ma-
chine.
Upon receipt of the machine our organization will
instruct you about correct operation and mainte-
nance.
Please observe strictly all safety regulations and
notes on potential dangers!
Fig. 1
Fig. 2
Fig. 3
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Table of Contents
BOMAG 5BP 12/40, BP 20/50, BP 25/50
Technical Data 7
Safety regulations 11
Indicators and Controls 15
3.1 General notes 16
3.2 Controls 16
Operation 19
4.1 General 20
4.2 Tests before taking into operation 20
4.3 Mounting the steering bow 21
4.4 Starting the engine 21
4.5 Work/operation 24
4.6 Switching the water sprinkling system on/off 25
4.7 Switching the motor off 25
4.8 Loading/transport 26
Maintenance 29
5.1 General notes on maintenance 30
5.2 Fuels and lubricants 31
5.3 Table of fuels and lubricants 32
5.4 Running-in instructions 33
5.5 Maintenance chart 34
5.6 Clean the machine 35
5.7 Check the engine oil level 35
5.8 Check the fuel level 36
5.9 Filling the water tank 37
5.10 Clean air filter 39
5.11 Clean the cooling fins and the cooling air intake openings 41
5.12 Engine oil change 43
5.13 Checking, cleaning the spark plug 44
5.14 Cleaning the fuel sludge filter 45
5.15 Clean the fuel screen 45
5.16 Check the V-belt, tighten, replace if necessary 46
5.17 Checking the Rubber Buffers 47
5.18 Check the oil level in the vibrator housing 48
5.19 Check, adjust the valve clearance 49
5.20 Change the oil in the vibrator housing 50
5.21 Change the dry air filter 51
5.22 Tightening the screws 52
5.23 Engine conservation 53
Trouble shooting 55
6.1 General notes 56
6.2 Engine problems 57
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BOMAG 7BP 12/40, BP 20/50, BP 25/50
1 Technical Data
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Technical Data
BOMAG8BP 12/40, BP 20/50, BP 25/50
Fig. 4
Dimensions in
mm
HH1 LL1 W
BP 12/40 663 962 1084 542 400
BP 20/50 663 962 1084 545 500
BP 25/50 663 962 1084 545 500
*BP 12/40 BP 20/50 BP 25/50
Weights
Basic weight kg 75 90 100
Operating weight (CECE) kg 82,5 91 100
Travel characteristics
Working speed max. m/min 25 25 25
Max. gradability (depending on soil) % 30 30 30
Drive
Engine manufacturer Honda Honda Honda
Type GX 160 GX 160 GX 160
Cooling Air Air Air
Working cycles 4 4 4
Number of cylinders 1 1 1
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Technical Data
BOMAG 9BP 12/40, BP 20/50, BP 25/50
Rated power ISO 9249 kW 4 4 4
Rated speed rpm 3600 3600 3600
Vibration system
Frequency Hz 90 90 90
Centrifugal force kN 12 20 25
Water sprinkling system**
Type of sprinkling Gravity feed Gravity feed Gravity feed
Water tank capacity l 11 15 15
Filling capacities
Fuel tank l 3,6 3,6 3,6
* The right for technical modifications remains reserved
** Optional equipment
*BP 12/40 BP 20/50 BP 25/50
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Technical Data
BOMAG10 BP 12/40, BP 20/50, BP 25/50
The following noise and vibration data acc. to
- EC Machine Regulation edition 98/37/EC and
- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC
- Vibration Protection Regulation 2002/44/EC
were determined during conditions typical for this type of equipment and by application of harmo-
nized standards.
During operation these values may vary because of the existing operating conditions.
Noise value
Sound pressure level at the place of operation:
BP 12/40: LpA = > 87 dB(A), determined acc. to ISO 11204 and EN 500
BP 20/50: LpA = > 87 dB(A), determined acc. to ISO 11204 and EN 500
BP 25/50: LpA = > 87 dB(A), determined acc. to ISO 11204 and EN 500
Guaranteed sound power level:
BP 12/40: LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500
BP 20/50: LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500
BP 25/50: LWA = 108 dB(A), determined acc. to ISO 3744 and EN 500
!Danger
Loss of hearing!
Wear your personal noise protection means (ear defenders) before starting operation.
Vibration value
Hand-arm vibration:
Vector total of the weighted effective acceleration in three orthogonal directions:
Weighted total vibration value
BP 12/40: ahw =x,xm/s
2on crushed rock determined acc. to ISO 5349 and EN 500
BP 20/50: ahw =x,xm/s
2on crushed rock determined acc. to ISO 5349 and EN 500
BP 25/50: ahw =x,xm/s
2on crushed rock determined acc. to ISO 5349 and EN 500
!
Caution
Observe the daily vibration load (Industrial safety acc. to 2002/44/EEC).
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BOMAG 11BP 12/40, BP 20/50, BP 25/50
2 Safety regulations
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Safety regulations
BOMAG12 BP 12/40, BP 20/50, BP 25/50
General
This BOMAG machine has been built in com-
pliance with the latest technical standard and
complies with the applicable regulations and
technical rules. However, dangers for persons
and property may arise from this machine, if:
lit is used for purposes other than the ones it is
intended for.
lit is operated by untrained personnel.
lit is changed or converted in an unprofessional
way.
lthe safety instructions are not observed.
Each person involved in the operation, mainte-
nance and repair of the machine must there-
fore read and comply with these safety
regulations. If necessary, this must be con-
firmed by obtaining the signature of the cus-
tomer.
Moreover, the following instructions and regula-
tions must obviously also be adhered to:
lapplicable accident prevention instructions,
lgenerally accepted safety and road traffic reg-
ulations,
lcountry specific safety regulations. It is the
duty of the operator to be acquainted with
these instructions and to apply these accord-
ingly. This applies also for local regulations
concerning different types of handling work.
Should the recommendations in these instruc-
tions be different from the regulations valid in
your country, you must comply with the safety
regulations valid in your country.
Intended use
This machine must only be used for:
lcompaction of all types of soil,
lrepair work on all types of soil,
lreinforcement of pedestrian walkways,
lwork in trenches,
lfilling and compaction of hard shoulders.
lThe machine should be checked by an expert
once every year.
Unintended use
Dangers may, however, arise from the machine if
it is used by untrained personnel in an unprofes-
sional way or if it is used for purposes other than
those mentioned in these instructions.
Who is allowed to work with the ma-
chine?
The machine must only be operated by trained
and authorized persons which are at least 18
years of age. The responsibilities for the operation
of the machine must be clearly specified and com-
plied with.
Persons under the influence of alcohol, medica-
tion or drugs must not operate, service or repair
the machine.
Maintenance and repair tasks require specific
knowledge and must therefore only be carried out
by trained and qualified personnel.
Changes and conversions to the ma-
chine
Unauthorized changes to the machine are not al-
lowed for safety reasons.
Original parts and accessories have been special-
ly designed for this machine. We wish to make ex-
plicitly clear that we have not tested or approved
any parts or accessories not supplied by us. The
installation and/or use of such products may have
an adverse effect on the active and/or passive
driving safety.
The manufacturer explicitly excludes any liability
for damage caused by the use of non-original
parts or accessories.
Safety notes in the operating and main-
tenance instructions:
!Danger
Sections marked like this point out possible
dangers for persons.
!
Caution
Sections marked like that point out possible
dangers for the machine or for parts of the ma-
chine.
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Safety regulations
BOMAG 13BP 12/40, BP 20/50, BP 25/50
i
Note
Sections marked like this provide technical infor-
mation concerning the optimal economical utiliza-
tion of the machine.
Safety stickers on the machine
Keep safety stickers in good condition and legible
and follow their meaning.
Replace damaged and illegible safety stickers.
Loading the machine
Secure the machine against turning over or slip-
ping off.
Persons are highly endagered if they
lstep or stand under loads being lifted,
lthe machine must not swing about when being
lifted.
Secure the machine on the transport vehicle
against rolling off, slipping and turning over.
Starting the machine
Before starting
Become acquainted with the equipment, the con-
trol elements, the working principle of the machine
and the working area.
Wear your personal protective outfit (hard hat,
safety boots, ear defenders, etc.).
Before starting the machine check whether:
lthe machine shows any obvious faults,
lall guards and safety elements are in place,
lthe controls are fully functional,
lthe machine is free of oily and combustible
material,
lall grips are free of grease, oils, fuel, dirt, snow
and ice.
Use only machines which are serviced at regular
intervals.
For starting move your feet out of the danger zone
of the base plate.
Do not use any starting aids like start pilot or ether.
Starting in closed rooms
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
in closed rooms!
Operation
Operate the machine only with the steering rod at-
tached.
Guide the machine so hat your hands do not hit
against solid objects, danger of injury.
Watch out for unusual noises and development of
smoke. Perform trouble shooting and have the
fault corrected.
Operate the machine only with full engine speed,
as otherwise the centrifugal clutch will be de-
stroyed.
Do not let the machine run unattended.
Parking the machine
Park the machine on level, firm ground.
Before leaving the machine:
lpark the machine so that it cannot turn over,
lshut the engine down.
Mark machines, which could be in the way, with a
clearly visible sign.
Filling in fuel
Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
Do not spill any fuel. Catch running out fuel, do not
let it seep into the ground.
Do not inhale any fuel fumes.
Do not fill the tank to the top.
Make sure that the tank lid is properly closed.
Maintenance work
Maintenance work must only be carried out by
qualified and authorized personnel.
Keep unauthorized persons away from the ma-
chine.
Do not perform service work while the engine is
running.
Park the machine on level and firm ground.
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Safety regulations
BOMAG14 BP 12/40, BP 20/50, BP 25/50
Working on the engine
Drain the engine oil at operating temperature -
danger of scalding!
Wipe off spilled oil, catch oil running out and dis-
pose of environmentally.
Store used filters and other oily material in a spe-
cially marked container and dispose of environ-
mentally.
Working on the fuel system
No open fire, do not smoke, do not spill any fuel.
Catch fuel running out, do not let it seep into the
ground and dispose of environmentally.
Cleaning
Do not clean the machine while the engine is run-
ning.
Do not use gasoline or other inflammable sub-
stances for cleaning purposes.
When using steam cleaning equipment do not
subject electric parts of the machine or insulation
materials to a direct jet of water, rather cover them
beforehand.
Do not guide the water jet into the air intake open-
ing.
After maintenance work
Always reattach all guards and safety devices
once all maintenance work is completed.
Repair
Repairs must only be carried out by qualified and
authorized personnel and by following our repair
instructions.
Exhaust gases are highly dangerous! Always en-
sure an adequate supply of fresh air when starting
the engine indoors!
Always mark defective machines by attaching a
sign to the steering rod.
Compaction machines must be checked by a spe-
cialist with respect to safety according to the appli-
cation and operating condition, but at least once
every year.
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BOMAG 15BP 12/40, BP 20/50, BP 25/50
3 Indicators and Controls
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Indicators and Controls
BOMAG16 BP 12/40, BP 20/50, BP 25/50
3.1 General notes
Please read this section thoroughly before operat-
ing this machine if you are not yet conversant with
the indicators and control elements. All functions
are described in detail hereunder.
Paragraph 4 Operation contains only concise de-
scriptions of the individual operating steps.
3.2 Controls
Fig. 5
No. 1 = Engine switch
Position "0" = Ignition off
Position "I" = Ignition on
Fig. 6
No. 2 = Starter rope with handle
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Indicators and Controls
BOMAG 17BP 12/40, BP 20/50, BP 25/50
Fig. 7
No. 3 = Choke
No. 4 = Fuel cock
Fig. 8
No. 5 = Throttle lever
Fig. 9
No. 6 = Shut-off tap for water sprinkling sys-
tem*
Position "OFF" = Sprinkling system switched off
Position "1/2" = Sprinkling switched on, half
the flow rate
Position "ON" = Sprinkling switched on, full
flow rate
No. 7 = Sprinkling system filling level indica-
tor
* Optional equipment
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BOMAG 19BP 12/40, BP 20/50, BP 25/50
4Operation
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Operation
BOMAG20 BP 12/40, BP 20/50, BP 25/50
4.1 General
If you are not yet acquainted with the controls
and indicating elements on this machine you
should thoroughly read chapter 3 “Indicators
and control elements” before starting work.
All indicators and control elements are de-
scribed in detail in this chapter.
4.2 Tests before taking into op-
eration
!Danger
Loss of hearing!
Wear your personal noise protection means
(ear defenders) before starting operation.
Strictly observe the safety regulations.
Refer also to the detailed description in the
maintenance instructions.
i
Note
The running in time of the vibratory plate is 25 op-
erating hours.
The following inspections must be carried out be-
fore each working day or before a longer working
period.
lPark the machine on level ground.
lTop up missing lubricants according to the
maintenance instructions.
lCheck fuel tank and fuel lines for leaks.
lCheck condition of engine and machine.
lCheck bolted connections for tight fit.
lCheck the engine oil level.
lCheck the fuel level.
lCheck the water level in the sprinkler system*.
* Optional equipment
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Operation
BOMAG 21BP 12/40, BP 20/50, BP 25/50
4.3 Mounting the steering bow
Fig. 10
lForce the steering bow (Fig. 10) apart and
plug it onto the bracket.
lAfter attaching the steering bow secure on
both sides with spring-type cotter pins.
4.4 Starting the engine
!
Caution
The engine is equipped with low oil level safety
shut-down. If the oil level is too low, the engine
cannot be started or it goes out during opera-
tion.
Fig. 11
lOpen the fuel cock (Fig. 11) by turning in direc-
tion of arrow to the end stop.
Fig. 12
lClose the choke completely by shifting the le-
ver (Fig. 12) in direction of arrow against the
end stop.
i
Note
Do NOT operate the choke lever when the engine
is warm or at high ambient temperatures. Also op-
erating position.
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